Application of polymer thermofoil to metal substrate

ABSTRACT

The present invention is directed to a novel method for application of polymer thermofoil to a metal substrate. The method involves first coating a metal substrate with an oxidation-preventing or oxidation-limiting coating, then adhering a polymer thermofoil to the metal substrate. After application of the thermofoil, the metal substrate can be formed to the final shape. The method is advantageous in that it allows one to efficiently manufacture metal objects in a variety of aesthetically pleasing surface finishes.

CLAIM OF PRIORITY

This application claims priority to U.S. 62/099,163.

BACKGROUND AND BRIEF SUMMARY OF THE INVENTION

The present invention is directed to a novel method for making metalcabinetry and other metal objects more aesthetically pleasing to the enduser. More particularly, the present invention involves the applicationof thermofoil surface finish to metal substrate as will be described ingreater detail below.

Thermofoil surface finish is well known in the cabinetry industry, sowill not be discussed in detail herein. However, briefly stated,thermofoil is a thin polymeric material (commonly a plasticizedpolyvinyl chloride) that is thermoformed, under vacuum pressure to asubstrate, thus giving the substrate a durable top coat or surfacefinish. Thermofoil comes in a number of finishes, including high and lowsheen, metallic-like finishes and faux wood grain finishes. The processof applying thermofoil generally involves the steps of (1) preparing thesubstrate, (2) applying adhesive to the substrate and/or thermofoil, (3)placing the thermofoil layer over the substrate, and (4) heating thethermofoil while under vacuum to cause the thermofoil to stretch andform to the underlying substrate (normally accomplished using a vacuummembrane press). Up to this point, thermofoil has generally been appliedto various wood-based surfaces since wood is easily contoured andshaped. However, the present invention discloses a novel method thatallows the application of thermofoil to an unformed metal substrate thatcan then be subsequently formed to a final product, thus resulting in amore aesthetically pleasing outcome.

As just mentioned, thermofoil is most commonly applied to a wood orfiberboard substrate. More particularly, it is frequently applied tomedium density fiberboard (MDF). Fiberboard lends itself well to suchapplications because it can be easily milled to different profiles overwhich the thermofoil can be applied. Thus, when used in cabinetryapplications, a faux wood grain thermofoil can be used to give theappearance of milled solid wood cabinetry at significantly reduced cost.The same is likewise true if a solid colored thermofoil is used—it givesthe appearance of painted solid wood, but provides a much more durablefinish than a painted surface, and can generally be done at a lowercost.

In contrast to wood-based substrates, working with thermofoil on metalsubstrates can be difficult for a number of reasons. Often, pre-formedor pre-machined metal substrates are shaped in such a way that it isimpossible to apply thermofoil to the part, or even if thermofoil can beapplied to the part, it is simply not practical to place these parts inthe vacuum membrane press during the thermofoil application process. Inaddition, because these parts are metal, they often have sharp edgesthat can easily damage the vacuum membrane press during thermofoilapplication. Because of these and other issues, thermofoil hashistorically not been used in applications in which it is applied to ametal substrate. Rather, paints, powder coatings, and the like havebecome the standard coating or covering used in finishing metalsurfaces.

In certain heavy-use applications, it is often beneficial to constructcabinetry out of metal. One preferred metal for use in manufacturingmetal cabinetry is steel, although aluminum or other metals or alloyscould be used in other embodiments of the present invention. Steelprovides superb durability as well as excellent strength when comparedto its weight. However, in certain applications the aesthetic appeal ofsteel cabinets finished in a single color paint or powder coat finish isnot ideal. To address this, manufacturers have previously offeredcabinetry comprising a steel cabinet body with cabinet doors made of MDFfinished with a faux wood grain thermofoil. The thermofoil cabinet doorsin combination with an appropriate countertop allows the cabinet to bemuch more aesthetically appealing, yet still sufficiently durable forheavy-use applications. While such an arrangement offers clearadvantages, it does not fully eliminate aesthetic concerns, as the metalbody of the cabinet is still unable to be offered in more aestheticallypleasing finishes such as faux wood grain or other finish selected tomatch accompanying cabinet doors.

The present invention addresses this need by providing a method ofapplying thermofoil to a metal substrate to produce an aestheticallypleasing result while also remaining relatively easy to apply andprocess.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 Flowchart depicting the steps involved in one preferredembodiment of the present invention.

FIG. 2 A cross-section of the finished product of one preferredembodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a novel process for applyingthermofoil to a metal substrate. More specifically, the presentinvention is directed to application of thermofoil to a painted, orcoated, metal substrate.

While the present invention is primarily focused on the use ofthermofoil-coated metal substrates in cabinetry, it will be understoodthat the methods described herein can also be used in non-cabinetryapplications, such as in automotive accessories, other householdaccessories, or other instances in which a thermofoil-coated metalsubstrate would beneficially provide both aesthetics and durability.

Turning now to a description of FIG. 1, there is shown a flow chartdepicting one preferred method of performing the process of the presentinvention. Each of the steps involved in the flow chart will bedescribed in greater detail below, including variations of these stepsthat also fall within the scope of the present invention.

In box 100, an initial metal blank is produced. By producing a metalblank it is meant that stock metal material (e.g., steel sheets or othersimilar starting material) is cut into the desired initial shape. In thecase of using metal sheets as the starting material, a blank can be cutfrom the sheets, with the blank including holes and other cutoutsrequired for the part to have the correct shape and features once itreaches its final form. For example, holes may be cut in the flat sheetfor later use in mounting hinges or other cabinetry hardware, mounting ashelf, or interlocking with other cabinet pieces. Alternatively, a metalblank can comprise a single flat sheet that is cut to final shape afterthe application of a polymer thermofoil to the flat sheet. However, itwill be understood that at this step the metal blank remains flat and isnot formed other than being cut. The cutting of the metal blank can beaccomplished using any methods commonly known in the art (e.g., plasma,press cutting or stamping, etc.)

Once the initial metal blank is produced it is then coated 102. Bycoated it is meant that the metal blank is covered on at least onesurface with some form of oxidation-preventing or oxidation-limitingcoating. Such coatings are well known in the art and includesolvent-based coatings, such as paints and epoxies, and dry coatingssuch as powder-based coatings that are heated after application to forma uniform surface covering. In one preferred embodiment, the metal blankis fully covered with a powder coating during this step. The advantagesof powder coating are many and are well known in the art, so will not bediscussed in detail herein. However, it will be noted that in undergoingthe coating process, the coating used will preferably have an elasticmodulus of low enough value to allow the metal blank to later undergobending without the coating developing cracks or other imperfections.Likewise, the adhesive properties between the coating and the metal willalso preferably be of sufficient strength to allow the metal blank to bebent and formed after coating without causing detachment of the coating.

It will be understood that the process of coating the metal blank alsoprovides aesthetic benefit. Specifically, while the outer surface of themetal blank will eventually be covered with thermofoil, fully coatingthe metal blank prevents any unfinished edges, inner surfaces, or otherbare metal surfaces from showing in the final product and also preventsoxidation of the underlying metal substrate, thus providing a moreaesthetically pleasing final product.

Once the metal blank is coated, a layer of adhesive is applied to atleast one surface of the metal blank 104. Specifically, the adhesive ispreferably applied to the surface to which the thermofoil will beaffixed. The adhesive can be a hot melt adhesive, solvent basedadhesive, or other standard adhesive known in the art. One commonadhesive used in such applications is a polyurethane-based moisturereactive curing hot melt adhesive. In one preferred embodiment of thepresent invention a pressure-sensitive hot melt adhesive is used.Application of the adhesive can be performed using techniques known inthe art such as direct application using a brush or other applicator orby use of a sprayer to apply an even coat of adhesive throughaerosolization and subsequent deposition on the desired surface.However, as with the step of coating the metal substrate, the adhesivepreferably has elastic properties that allow it to undergo bending andforming without losing adhesion or failing in some other manner.

After application of the adhesive, a sheet of thermofoil covering isapplied to the surface of the metal blank 106 on which the adhesive wasapplied in the prior step. The thermofoil is then adhered to the surfaceof the metal blank. As noted above, in one preferred embodiment of thepresent invention, a pressure sensitive hot melt adhesive is used tobond the thermofoil to the metal blank. In this case the metal blank isheated and pressure is applied in order to attach the thermofoil to themetal blank. Because the metal blank is still flat during this step, avacuum membrane press is unnecessary since there are no surface contourson the metal blank to which the thermofoil needs to conform. Rather, aroller, a press, or other similar apparatus can be used to applypressure to the thermofoil to ensure that proper adhesion occurs. Thisalso provides efficiency in manufacturing since such an approacheliminates the need for a manufacturer to invest in a vacuum membranepress. It will be understood, however, that in certain embodiments ofthe present invention the metal blank may have certain surface contoursformed in the metal through the use of presses, dies, etc., and in theseinstances a vacuum membrane press could be required to ensure that thethermofoil becomes properly attached to the underlying metal blank.

As with the above-noted coating, the thermofoil preferably exhibitsmechanical properties that allow it to undergo bending and formingwithout cracking or otherwise detaching from the underlying metal blank.Specifically, the thermofoil preferably has an elastic modulus of lowenough value to allow it to later undergo bending to angles greater than90 degrees without the thermofoil developing cracks, but high enoughthat the thermofoil does not easily take on permanent impressions orother surface imperfections from the forces involved in being in contactwith the forming equipment used to shape the metal blank into its finalform.

Once the thermofoil has been adhered to the surface of the metal blank,the excess thermofoil must be trimmed 108 from the edges as well as anyneeded openings included in the metal blank (e.g., a slot or hole usedfor supporting a shelf after assembly). The trimming process can be donemanually or with the use of automated equipment set to properly indexand trim each metal blank. Methods for trimming excess thermofoil arewell known in the art and will thus not be addressed in further detailherein. Alternatively, if the metal blank from step 100 is simply a flatsheet that has been fully coated with thermofoil, the trimming processof step 108 can comprise the cutting of both the thermofoil and metalblank to the final dimensions prior to forming.

Up to this point in the process, it will be noted that the metal blank,or metal substrate, comprises a flat, or 2-dimensional, object. However,after the trimming step 108, the forming process is begun 110. Throughuse of press brakes and other metal forming tools and equipment known inthe art, the metal blank is formed into its final 3-dimensional shape,with care being taken not to damage the softer thermofoil coveringduring the forming process. Final shape can vary widely depending on thefinal structure needed and the mechanical strength needed when the metalblank is assembled as part of the final product Critically, however, ithas been observed that during the forming process the thermofoil willdevelop stress markings indicated by a whitening of the thermofoilcovering near, or over, the point(s) where the metal blank is bent orotherwise formed. This whitening is the result of the applied stresscausing shifting of the molecular bonds of the thermofoil. Thisphenomenon is often referred to as crazing. This whitening is notdesirable from an aesthetic standpoint as it causes inconsistencies inthe finish of the final product. To address this whitening, the methodof the present invention includes the step of heating the metal blankafter forming 112. This heating allows the local stress causing thewhitening of the thermofoil to be relieved and thus eliminates thestress whitening, returning the thermofoil to its original finish.Heating is preferably done to a point below the melting point of thethermofoil and to a temperature relatively near to, or higher than theglass transition temperature of the thermofoil. In an alternativeembodiment of the present invention, the thermofoil-covered metal blankmay be heated during the forming process as a way of eliminating orreducing the occurrence of stress whitening during the forming process.In still another alternative embodiment, the color of the thermofoil canbe such that the stress whitening does not aesthetically affect thefinal product, or the thermofoil can be formulated to withstand bendingwith minimal or no stress whitening in either case, it will beunderstood that heating of the thermofoil blank would be unnecessaryunder these circumstances and that such a step could then be omittedfrom the method.

Once the stress whitening has been eliminated (if present), the metalblank is considered finished 114. If the metal blank is a smaller partof a larger final product, it can then be assembled as part of the finalproduct.

Turning now to FIG. 2, there is shown a cross section of a completedmetal blank 128. It will be noted that FIG. 2 is not drawn to scale. Asillustrated in FIG. 2, a metal substrate 120 is coated with anoxidation-preventing or oxidation-limiting coating 122. As mentionedabove, such coatings are well known in the art and include solvent-basedcoatings, such as paints and epoxies, and dry coatings such aspowder-based coatings that are heated after application to form auniform surface coating. An adhesive layer 124 is also shown, bondingthe thermofoil 126 to the coated metal substrate 120, 122.

While the above description has focused primarily on application ofpolymer thermofoil to a precut metal blank, it will also be understoodthat in other embodiments of the present invention entire sheets ofstock material could be covered with thermofoil using the above processand then subsequently cut into appropriate blanks for later forming intofinished parts as already mentioned above.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the present inventionwithout departing from the spirit and scope of the invention as setforth in the above description. Thus, it is intended that the presentinvention cover the modifications and variations of this inventionprovided they come within the scope of the invention and itsequivalents.

What is claimed is:
 1. A method for manufacturing a thermofoil covered metal substrate, the method comprising the steps of: coating at least one surface of a metal substrate with an oxidation-preventing or oxidation-limiting coating; applying adhesive to at least one surface of the coated metal substrate, applying a thermofoil sheet to the adhesive, thus causing the thermofoil sheet to adhere to the metal substrate; and forming the metal substrate into a desired final shape.
 2. The method of claim 1 wherein the adhesive applied to the at least one surface of the coated metal substrate comprises a hot melt adhesive.
 3. The method of claim 1 wherein the method further includes a final step of heating the metal substrate after the step of forming the metal substrate into a desired final shape.
 4. The method of claim 1 wherein the oxidation-preventing coating comprises a powder-based coating.
 5. The method of claim 1 wherein the thermofoil sheet comprises polyvinyl chloride.
 6. The method of claim 1 wherein the step of forming the metal substrate into a desired final shape is accomplished using a press brake.
 7. A method for manufacturing a thermofoil-covered metal substrate, the method comprising the steps of: producing a metal blank; coating at least one surface of the metal blank with an oxidation-preventing or oxidation-limiting coating; applying adhesive to at least one surface of the coated metal blank; applying a thermofoil sheet to the adhesive, thus causing the thermofoil sheet to adhere to the metal blank; trimming any excess thermofoil from the metal blank; and forming the metal blank into a desired final shape.
 8. The method of claim 7 wherein the adhesive applied to the at least one surface of the coated metal substrate comprises a hot melt adhesive.
 9. The method of claim 7 wherein the method further includes a final step of heating the metal blank after the step of forming the metal blank into a desired final shape.
 10. The method of claim 7 wherein the oxidation-preventing coating comprises a powder-based coating.
 11. The method of claim 7 wherein the thermofoil sheet comprises polyvinyl chloride.
 12. The method of claim 7 wherein the step of forming the metal blank into a desired final shape is accomplished using a press brake.
 13. A method for manufacturing a thermofoil-covered metal substrate, the method comprising: coating at least one surface of a metal sheet with an oxidation-preventing or oxidation-limiting coating; applying adhesive to the oxidation-preventing or oxidation-limiting coating; applying a thermofoil sheet to the adhesive, thus causing the thermofoil sheet to adhere to the metal sheet; cutting the thermofoil-covered metal sheet to a shape conducive to forming the metal sheet to a desired final shape; and forming the cut metal sheet into a desired final shape.
 14. The method of claim 13 wherein the adhesive applied to the oxidation-preventing or oxidation-limiting coating comprises a hot melt adhesive.
 15. The method of claim 13 wherein the method further includes a final step of heating the formed metal sheet after the step of forming into a desired final shape.
 16. The method of claim 13 wherein the oxidation-preventing coating comprises a powder-based coating.
 17. The method of claim 13 wherein the thermofoil sheet comprises polyvinyl chloride.
 18. The method of claim 13 wherein the step of forming the metal blank into a desired final shape is accomplished using a press brake. 